ok total newb question. So I have some 18 gauge sheet metal that I want to cut into 1" x 4" pieces, and then bend those pieces to a specific profile...they need to be more or less all the same.

I did it ghetto-like in a vice, hammer, and some bigger chunks of bar stock...but it obviously came out pretty shitty.

So I was thinking of taking a 2 pieces of 1/2" plate, welding them/sandwiching them together, and then cutting the profile of the bend I want to make with the plasma cutter. Clean it up with the grinder obviously. Then use the other half and clean it up so it matches up with the first part. Then place my pre-cut piece of sheet metal in between them and put it in the shop hydraulic press and squeeze it together...theoretically that would make some half-ass decently repeatable brackets no? Or is this totally stupid and theres an easier way to do it?

The drawing sucks but you get the idea. :flipoff2:

ben

Typically a properly engineered die (one which would leave you wil very little if any tearing or thin spots from material movement) takes into consideration the thickness of the material your bending or stamping. So if you have a cad drawing and your going to bend 1/4 in some crazy pattern you actually take 1/8" from the surface of each side of the die. You can get close enough not including material thickness in your die but it all depends on the shape.

Hope that helps.

Typically a properly engineered die (one which would leave you wil very little if any tearing or thin spots from material movement) takes into consideration the thickness of the material your bending or stamping. So if you have a cad drawing and your going to bend 1/4 in some crazy pattern you actually take 1/8" from the surface of each side of the die. You can get close enough not including material thickness in your die but it all depends on the shape.

Hope that helps.

nahh it doesnt have to be anywhere near that technical/precise. :)

I think it would be very repeatable until it wears out.

have you talked to a local machine shop about possibly milling these out for you, something that small should'nt cost a fortune...

What thickness guage of metal are you looking at using. If it is thin enough then you can probably get away with a Wood form and press it in a 12 ton or larger break.

Worth a try. You can always go back and make it with steel. I would suggest a good hard wood like Oak with a fine grain structure.

A lot of the Sheet Metal guys make their bucks out of wood.


Carl

The easier way to do it would be to draw it up so bends are compensated for, bang out the blanks on the shear then finish them up on a brake. :flipoff2:

If you want pm me your dimensions and I'll send you a print with the appropriate blank size and accurate bend locations. ;)

keep in mind any spring back issues in your die angles vs. finished part bend angles. Won't be as bad in lighter materials, but still a factor.

ok total newb question. So I have some 18 gauge sheet metal that I want to cut into 1" x 4" pieces, and then bend those pieces to a specific profile...they need to be more or less all the same.

I did it ghetto-like in a vice, hammer, and some bigger chunks of bar stock...but it obviously came out pretty shitty.

So I was thinking of taking a 2 pieces of 1/2" plate, welding them/sandwiching them together, and then cutting the profile of the bend I want to make with the plasma cutter. Clean it up with the grinder obviously. Then use the other half and clean it up so it matches up with the first part. Then place my pre-cut piece of sheet metal in between them and put it in the shop hydraulic press and squeeze it together...theoretically that would make some half-ass decently repeatable brackets no? Or is this totally stupid and theres an easier way to do it?

The drawing sucks but you get the idea. :flipoff2:

ben

What thickness guage of metal are you looking at using. If it is thin enough then you can probably get away with a Wood form and press it in a 12 ton or larger break.

Worth a try. You can always go back and make it with steel. I would suggest a good hard wood like Oak with a fine grain structure.

A lot of the Sheet Metal guys make their bucks out of wood.


Carl

Aw, I think he is wanting to bend 18 gauge with it..

Got access to a bandsaw or portaband? If so I would try to do the profile cut on it instead of with the plasma. On 1" you better have a beefy plasma and a steady hand to get a good edge.

Your actually getting some good advice here. MC gives you the truth if want it to look nice and not tear, bend..basically look like crap.

If you want good stuff the surfaces of the top and the bottom dies need to be pretty precise..otherwise it will not even close, or will break while trying to close it.

That "ghetto" drawing is like something my boss would quote..(he is a salesman, not a tool maker) all the mostly relevant stuff is missing, like angles.:flipoff2:

If your only going to make a few I would use wood as suggested. You will need a good piece to get that deep angle but it should be easier to work with than steel. You might not get as sharp as an included angle as you want though, will prolly be more radius in the hard corners, but cutting those angles in wood is much easier with limited tools..and way faster to make. You also have the advantage of wood having a certain amount of "give" before it breaks.

If you want 50 or more then use steel and be prepared to have a experienced person build it.

Making a good stamping die is not easy, I have built plenty...but everyone thinks that a coke can just appears from the coke fairy...they don't realize that coke spent +200k on each die to makes those cans.

Got access to a bandsaw or portaband? If so I would try to do the profile cut on it instead of with the plasma. On 1" you better have a beefy plasma and a steady hand to get a good edge.

my metal band saw is all taken apart. :(

the plasma cutter will do 1", but yeah its messy at that thickness. The wood might be worth a shot. Ill try it with some ipe which is pretty hard stuff.

Appreciate all the help, Ill try it tomorrow after work.

Ben